US4900589A - Granule application device and process - Google Patents

Granule application device and process Download PDF

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Publication number
US4900589A
US4900589A US07/241,284 US24128488A US4900589A US 4900589 A US4900589 A US 4900589A US 24128488 A US24128488 A US 24128488A US 4900589 A US4900589 A US 4900589A
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headlap
granules
sheet
applicator
recycle
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US07/241,284
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Donald Montgomery
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Building Materials Corp of America
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GAF Building Materials Corp
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Assigned to GAF CORPORATION, 1361 ALPS ROAD, WAYNE, NEW JERSEY 07470, A CORP. OF DE reassignment GAF CORPORATION, 1361 ALPS ROAD, WAYNE, NEW JERSEY 07470, A CORP. OF DE ASSIGNMENT OF ASSIGNORS INTEREST. Assignors: MONTGOMERY, DONALD
Application filed by GAF Building Materials Corp filed Critical GAF Building Materials Corp
Priority to US07/241,284 priority Critical patent/US4900589A/en
Assigned to CHASE MANHATTAN BANK (NATIONAL ASSOC.) THE reassignment CHASE MANHATTAN BANK (NATIONAL ASSOC.) THE SECURITY INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: EDGECLIFF INC.
Assigned to CHASE MANHATTAN BANK, THE NATIONAL ASSOCIATION reassignment CHASE MANHATTAN BANK, THE NATIONAL ASSOCIATION SECURITY INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: DORSET INC. A CORP OF DELAWARE
Priority to AU43158/89A priority patent/AU4315889A/en
Priority to PCT/US1989/003571 priority patent/WO1990002609A1/en
Assigned to GAF BUILDING MATERIALS CORPORATION, A CORP. OF DE reassignment GAF BUILDING MATERIALS CORPORATION, A CORP. OF DE ASSIGNMENT OF ASSIGNORS INTEREST. Assignors: GAF CORPORATION
Publication of US4900589A publication Critical patent/US4900589A/en
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Assigned to CHASE MANHATTAN BANK, THE, (NATIONAL ASSOCIATION) reassignment CHASE MANHATTAN BANK, THE, (NATIONAL ASSOCIATION) SECURITY INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: GAF BUILDING MATERIALS CORPORATION, A CORP. OF DE
Assigned to GAF BUILDING MATERIALS CORPORATION, SUTTON LABORATORIES, INC., GAF CHEMICALS CORPORATION reassignment GAF BUILDING MATERIALS CORPORATION RELEASED BY SECURED PARTY (SEE DOCUMENT FOR DETAILS). Assignors: CHASE MANHATTAN BANK, THE (NATIONAL ASSOCIATION)
Assigned to BUILDING MATERIALS CORPORATION OF AMERICA reassignment BUILDING MATERIALS CORPORATION OF AMERICA CHANGE OF NAME (SEE DOCUMENT FOR DETAILS). Assignors: GAF NEWCO INC.
Assigned to GAF NEWCO INC. reassignment GAF NEWCO INC. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: GAF BUILDING MATERIALS CORPORATION
Assigned to BANK OF NEW YORK, THE, AS COLLATERAL AGENT reassignment BANK OF NEW YORK, THE, AS COLLATERAL AGENT GRANT OF SECURITY INTEREST (PATENTS) Assignors: BUILDING MATERIALS CORPORATION OF AMERICA
Assigned to CITIBANK, N.A. reassignment CITIBANK, N.A. SECURITY INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: BMCA INSULATION PRODUCTS INC., BUILDING MATERIALS CORPORATION OF AMERICA, BUILDING MATERIALS INVESTMENT CORPORATION, BUILDING MATERIALS MANUFACTURING CORPORATION, DUCTWORK MANUFACTURING CORPORATION, GAF LEATHERBACK CORP., GAF MATERIALS CORPORATION (CANADA), GAF PREMIUM PRODUCTS INC., GAF REAL PROPERTIES, INC., GAFTECH CORPORATION, LL BUILDING PRODUCTS INC., PEQUANNOCK VALLEY CLAIM SERVICE COMPANY, INC., SOUTH PONCA REALTY CORP., WIND GAP REAL PROPERTY ACQUISITION CORP.
Assigned to BUILDING MATERIALS CORPORATION OF AMERICA reassignment BUILDING MATERIALS CORPORATION OF AMERICA TERMINATION AND RELEASE OF SECURITY INTEREST Assignors: BANK OF NEW YORK, THE
Assigned to GAF REAL PROPERTIES, INC., GAF MATERIALS CORPORATION (CANADA), GAF LEATHERBACK CORP., GAFTECH CORPORATION, BUILDING MATERIALS MANUFACTURING CORPORATION, BMCA INSULATION PRODUCTS, INC., BUILDING MATERIALS INVESTMENT CORPORATION, PEQUANNOCK VALLEY CLAIM SERVICE COMPANY, INC., WIND GAP REAL PROPERTY ACQUISITION CORP., BUILDING MATERIALS CORPORATION OF AMERICA, GAF PREMIUM PRODUCTS, INC., LL BUILDING PRODUCTS, INC., DUCTWORK MANUFACTURING CORPORATION, SOUTH PONCA REALTY CORP. reassignment GAF REAL PROPERTIES, INC. RELEASE BY SECURED PARTY (SEE DOCUMENT FOR DETAILS). Assignors: CITIBANK, N.A.
Assigned to DEUTSCHE BANK TRUST COMPANY AMERICAS reassignment DEUTSCHE BANK TRUST COMPANY AMERICAS SECURITY AGREEMENT Assignors: BMCA ACQUISITION INC., BMCA ACQUISITION SUB INC., BMCA FRESNO II LLC, BMCA FRESNO LLC, BMCA GAINESVILLE LLC, BMCA INSULATION PRODUCTS INC., BMCA QUAKERTOWN INC., BUILDING MATERIALS CORPORATION OF AMERICA, BUILDING MATERIALS INVESTMENT CORPORATION, BUILDING MATERIALS MANUFACTURING CORPORATION, DUCTWORK MANUFACTURING CORPORATION, GAF LEATHERBACK CORP., GAF MATERIALS CORPORATION (CANADA), GAF PREMIUM PRODUCTS INC., GAF REAL PROPERTIES, INC., GAFTECH CORPORATION, HBP ACQUISITION LLC, LL BUILDING PRODUCTS INC., PEQUANNOCK VALLEY CLAIM SERVICE COMPANY, INC., SOUTH PONCA REALTY CORP., WIND GAP REAL PROPERTY ACQUISITION CORP.
Assigned to DEUTSCHE BANK AG NEW YORK BRANCH reassignment DEUTSCHE BANK AG NEW YORK BRANCH SECURITY AGREEMENT Assignors: BMCA ACQUISITION INC., BMCA ACQUISITION SUB INC., BMCA FRESNO II LLC, BMCA FRESNO LLC, BMCA GAINESVILLE LLC, BMCA INSULATION PRODUCTS INC., BMCA QUAKERTOWN INC., BUILDING MATERIALS CORPORATION OF AMERICA, BUILDING MATERIALS INVESTMENT CORPORATION, BUILDING MATERIALS MANUFACTURING CORPORATION, DUCTWORK MANUFACTURING CORPORATION, GAF LEATHERBACK CORP., GAF MATERIALS CORPORATION (CANADA), GAF PREMIUM PRODUCTS INC., GAF REAL PROPERTIES, INC., GAFTECH CORPORATION, HBP ACQUISITION LLC, LL BUILDING PRODUCTS INC., PEQUANNOCK VALLEY CLAIM SERVICE COMPANY, INC., SOUTH PONCA REALTY CORP., WIND GAP REAL PROPERTY ACQUISITION CORP.
Assigned to EDGECLIFF INC. reassignment EDGECLIFF INC. NUNC PRO TUNC COLLATERAL RELEASE Assignors: THE CHASE MANHATTAN BANK
Assigned to DORSET INC. reassignment DORSET INC. NUNC PRO TUNC COLLATERAL RELEASE Assignors: THE CHASE MANHATTAN BANK
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05C—APPARATUS FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05C19/00—Apparatus specially adapted for applying particulate materials to surfaces

Definitions

  • the invention relates to a granule application device, and in particular the invention relates to a granule application device having three granule applicators for making shingle roofing products.
  • the prior art granule application devices generally include a blender applicator with a recycle applicator disposed immediately downstream of the applicator and a sheet for travelling under these applicators to receive the granules.
  • the headlap applicator is arranged with a dispensing control between the blender applicator and the recycle applicator to minimize the recycle volume of the expensive granules from the blender applicator and for increasing the recycled volume of the less expensive granules from the headlap applicator.
  • This arrangement avoids the problem of recycling a substantial volume of expensive granules from the blender applicator into the recycle applicator from the travelling sheet.
  • FIG. 1 is a schematic perspective view of a granule application device according to the invention
  • FIG. 2 is an elevation view of the granule application device of FIG. 1;
  • FIG. 3 is a section view taken along the line 3--3 of FIG. 2;
  • FIG. 4 is a section view taken along the line 4--4 of FIG. 2;
  • FIG. 5 is a top view of the granule bin arrangement.
  • a granule application device for use in making a shingle roofing product is generally indicated at 10.
  • the device includes a backfall or recycle applicator 12, a headlap applicator 14, a variegated or blender applicator 16.
  • a web or sheet 18 travels under the applicators 12, 14 and 16 for receiving granules from the applicators.
  • FIG. 2 shows the sheet 18 supported by a talc drum or roll 20, a slate drum or roll 22, and a seal drum or roll 26. All the drums 20, 22 and 26 are mounted on a support structure 28, which rests on a concrete floor 30.
  • granules are fed from bins 33, 38, 50 and 60. Each bin is divided into sections or blender bins.
  • the recycle applicator 12 is fed granules from bin 33 through drop tubes 31A, 31B, 32A and 32B located in backfall bins 33A through 33D.
  • the recycle applicator 12 is also fed granules by drop tubes 34, 35, 36, 37 from scrap bins 38C and 38D.
  • the headlap applicator 14 is fed by drop tubes 39, 40, 41, 42 from headlap bins 38A and 38B.
  • the blender applicator 16 is fed by drop tubes 43, 44, 46, 48 from blender bins 50A through 50D.
  • the blender applicator 16 is also fed by drop tubes 52, 54, 56, 58 from blender bins 60A through 60D.
  • the granule application device 10 also has a seal back wiper 62, which is disposed adjacent to a seal roll 26 which can be used for applying a back coating.
  • the granule application device 10 also has a recycle slate conveyor 64, which is disposed near to the recycle applicator 12 and the scrap bins 38C and 38D.
  • the conveyor 64 has an input recycle chute 63.
  • the recycle applicator 12 also has an input recycle chute 65.
  • recycle applicator 12 has compartments or chambers 66, 68, 70, 72, 74.
  • the headlap applicator 14 has similar chambers 76, 78, 80.
  • the blender applicator 16 also has similar chambers 82 84, 86, 88, 90, 92, 94, 96.
  • the recycle applicator 12 has a machine driven roll and gate unit 98.
  • the headlap applicator 14 has a manually operable roll and gate unit 100.
  • the blender applicator 16 also has four machine driven roll and gate units 102, 104, 106, 108.
  • roll and gate units 98, 100, 102, 104, 106, 108 have respective adjacent deflector plates 110, 112, 114, 116, 118 and 120 for deflecting the granules during their fall.
  • the manually operable roll and gate unit 100 is a variable speed unit, and it is independent of the speed of a machine drive.
  • the gate is opened by manual control.
  • the roll and gate unit 98 connects to a machine drive (not shown) by a varigator link unit 99.
  • the roll and gate unit 100 has a manually operated D.C. control unit 101.
  • the roll and gate units 102, 104, 106 and 108 are also mechanically linked to the machine (not shown), so that a speed change of sheet 18 will cause a proportional speed change in the flow of granules from the blender applicator 16, and from the recycle applicator 12. In this way, a respective constant thickness of granules are applied by the blender applicator 16 and by the recycle applicator 12 on sheet 18, regardless of the speed of travel of sheet 18.
  • the deflector plate 112 of the headlap applicator 14 is shown.
  • the plate 112 has three flat guide portions 124, 125, 126, a bent portion 127, two protected backfall zones 128, 129, and directional guides 130, 131, 132, 133.
  • the device 10 has a cutter unit 134, which is disposed downstream of drum 20.
  • the device also has a coater assembly 136, which is disposed upstream of the roll 26.
  • the cutter unit 134 cuts sheet 18 into pieces to form shingles.
  • a coater assembly 136 applies a conventional sticky material, such as asphalt, to the facing surface of sheet 18 prior to the application of the granules.
  • the blender applicator 16 applies blended prime butt granules to the surface of the sheet 18 only in the exposed drop areas of the butt.
  • the headlap applicator 14 then applies virgin granules to the headlap area which had not been exposed to the blender applicator.
  • the backfall applicator 12 then applies a general coverage of granules across the entire surface of the sheet using a combination of recycled granules and virgin make-up granules.
  • the backfall box of the backfall applicator is zoned so that the combined recycle headlap granules and virgin headlap granules are applied only in the headlap zones on the sheet.
  • the headlap applicator applies a thickness of less expensive headlap granules only on the non-exposed headlap area of the surface of the sheet; so that the headlap area of the surface of the sheet will ultimately have a double thickness of granules.
  • the thickness of granules is adjusted by manual operation of control unit 101.
  • the granules applied to the non-exposed headlap area of the sheet by means of the deflector plate 112 are applied in controlled distinctive lines.
  • the recycle applicator 12 applies a uniform thickness of granules to the surface of the sheet.
  • the sheet width is about forty eight inches, which includes two outer six inch wide headlap strips and one center twelve inch wide headlap strip and two intermediate twelve inch wide weather exposed butt strips, so that sheet can be cut along three cutting lines to form four longitudinal shingle strips.
  • the recycle applicator 12, which is about forty eight inches wide has two outer six inch wide chambers 66, 74 with recycle or scrap granules for the two outer six inch wide headlap strips.
  • the recycle applicator 12 also has one center twelve inch wide chamber 70 with recycle or scrap granules for the one center 12 inch wide headlap strip.
  • the recycle applicator 12 also has two intermediate twelve inch wide chambers 68, 72 with clean new backfall granules for the two intermediate twelve inch wide weather exposed butt strips.
  • the varigator link unit 99 is adjusted, to provide just slightly more new backfall granules to the exposed butt area than will be imbedded and accepted by the coated sheet 18.
  • a typical process of manufacture utilizing the granule application device 10 is as follows.
  • a sticky, asphalt material is applied over the total facing area of sheet 18 by coater assembly 136.
  • the blender applicator 16 dispenses blended granules over the butt area of sheet 18.
  • the headlap applicator 14 then dispenses headlap granules over the headlap area of the sheet 18 at a rate of flow as set by an operator.
  • the recycle applicator 12 dispenses recycled granules over the headlap granules and the butt (exposed) area on sheet 18.
  • the blender applicator 16 and recycle applicator 12 are machine driven and dispense at a rate of flow in proportion to the rate of movement of sheet 18.
  • Cutter unit 134 then cuts sheet 18 into elongate shingle strips by a peripheral blade, and into pieces by a transverse blade, at a rate in proportion to the speed of movement of sheet 18.
  • the total area available in the non-exposed headlap area is covered with less expensive headlap granules by the headlap applicator 14; and there is substantially no contamination of headlap granules in the exposed butt area.

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Abstract

A granule application device for use in making a shingle roofing product is provided. This device includes a sheet having a weather protected headlap area and having a weather exposed butt area which moves continuously from an upstream end to a downstream end. The device includes a blender applicator which dispenses blended butt granules on the sticky, asphalt treated, upper surface of the sheet for covering the butt area only. The device also includes a headlap applicator which dispenses less expensive headlap granules on the headlap area only. The device also includes a recycle applicator, which dispenses recycle granules over the blended granules on the butt area only, and dispenses scrap granules over the headlap area only. The moving sheet is supported on a talc drum and a slate drum near the downstream end, and is supported on a back roll near the upstream end thereof. The manual control of the dispensing of the less expensive headlap granules, and the overall arrangement, reduces the percentage of more expensive blended granules in the recycled granules, thereby minimizing the overall cost of the shingle roofing product.

Description

The invention relates to a granule application device, and in particular the invention relates to a granule application device having three granule applicators for making shingle roofing products.
BACKGROUND OF THE INVENTION
The prior art granule application device is described in U.S. Pat. No. 4,478,869, issued Oct. 23, 1984. Related disclosures appear in U.S. Pat. Nos. 1,669,166, issued May 8, 1928; 2,111,565, issued Mar. 22, 1938; 2,160,787, issued May 30, 1939; 2,211,204, issued Aug. 13, 1940; 2,233,122, issued Feb. 25, 1941; 2,356,570, issued Aug. 22, 1944; 2,400,746, issued May 21, 1946; 2,661,303, issued Dec. 1, 1953; 3,132,964, issued May 12, 1964; 3,184,324, issued May 18, 1965; and 4,352,837, issued Oct. 5, 1982.
The prior art granule application devices generally include a blender applicator with a recycle applicator disposed immediately downstream of the applicator and a sheet for travelling under these applicators to receive the granules.
One of the basic problems with the prior art granule application device is that a substantial volume of expensive granules from the blender applicator have to be recycled into a recycle applicator from the travelling sheet.
SUMMARY OF THE INVENTION According to the present invention, a granule application device is provided for applying granules to a travelling sheet which includes a blender applicator, a recycle applicator, a headlap applicator and a dispensing control disposed between the blender applicator and the recycle applicator.
The headlap applicator is arranged with a dispensing control between the blender applicator and the recycle applicator to minimize the recycle volume of the expensive granules from the blender applicator and for increasing the recycled volume of the less expensive granules from the headlap applicator. This arrangement avoids the problem of recycling a substantial volume of expensive granules from the blender applicator into the recycle applicator from the travelling sheet.
The foregoing and other objects, features and advantages of the invention will be apparent from the following detailed description of the preferred embodiment of the invention.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic perspective view of a granule application device according to the invention;
FIG. 2 is an elevation view of the granule application device of FIG. 1;
FIG. 3 is a section view taken along the line 3--3 of FIG. 2;
FIG. 4 is a section view taken along the line 4--4 of FIG. 2; and
FIG. 5 is a top view of the granule bin arrangement.
DESCRIPTION OF THE PREFERRED EMBODIMENT
As shown in FIGS. 1 and 2 of the drawing, a granule application device for use in making a shingle roofing product is generally indicated at 10. The device includes a backfall or recycle applicator 12, a headlap applicator 14, a variegated or blender applicator 16. A web or sheet 18 travels under the applicators 12, 14 and 16 for receiving granules from the applicators.
FIG. 2 shows the sheet 18 supported by a talc drum or roll 20, a slate drum or roll 22, and a seal drum or roll 26. All the drums 20, 22 and 26 are mounted on a support structure 28, which rests on a concrete floor 30.
Referring to FIGS. 2, 3 and 5, granules are fed from bins 33, 38, 50 and 60. Each bin is divided into sections or blender bins. The recycle applicator 12 is fed granules from bin 33 through drop tubes 31A, 31B, 32A and 32B located in backfall bins 33A through 33D. The recycle applicator 12 is also fed granules by drop tubes 34, 35, 36, 37 from scrap bins 38C and 38D. The headlap applicator 14 is fed by drop tubes 39, 40, 41, 42 from headlap bins 38A and 38B. The blender applicator 16 is fed by drop tubes 43, 44, 46, 48 from blender bins 50A through 50D. The blender applicator 16 is also fed by drop tubes 52, 54, 56, 58 from blender bins 60A through 60D.
As shown in FIG. 2, the granule application device 10 also has a seal back wiper 62, which is disposed adjacent to a seal roll 26 which can be used for applying a back coating. The granule application device 10 also has a recycle slate conveyor 64, which is disposed near to the recycle applicator 12 and the scrap bins 38C and 38D. The conveyor 64 has an input recycle chute 63. The recycle applicator 12 also has an input recycle chute 65.
In FIG. 3, recycle applicator 12 has compartments or chambers 66, 68, 70, 72, 74. The headlap applicator 14 has similar chambers 76, 78, 80. The blender applicator 16 also has similar chambers 82 84, 86, 88, 90, 92, 94, 96. In FIG. 2, the recycle applicator 12 has a machine driven roll and gate unit 98. The headlap applicator 14 has a manually operable roll and gate unit 100. The blender applicator 16 also has four machine driven roll and gate units 102, 104, 106, 108.
In FIG. 2, roll and gate units 98, 100, 102, 104, 106, 108 have respective adjacent deflector plates 110, 112, 114, 116, 118 and 120 for deflecting the granules during their fall.
The manually operable roll and gate unit 100 is a variable speed unit, and it is independent of the speed of a machine drive. The gate is opened by manual control.
The roll and gate unit 98 connects to a machine drive (not shown) by a varigator link unit 99. The roll and gate unit 100 has a manually operated D.C. control unit 101. The roll and gate units 102, 104, 106 and 108 are also mechanically linked to the machine (not shown), so that a speed change of sheet 18 will cause a proportional speed change in the flow of granules from the blender applicator 16, and from the recycle applicator 12. In this way, a respective constant thickness of granules are applied by the blender applicator 16 and by the recycle applicator 12 on sheet 18, regardless of the speed of travel of sheet 18.
In FIG. 4, the deflector plate 112 of the headlap applicator 14 is shown. The plate 112 has three flat guide portions 124, 125, 126, a bent portion 127, two protected backfall zones 128, 129, and directional guides 130, 131, 132, 133.
In FIG. 2, the device 10 has a cutter unit 134, which is disposed downstream of drum 20. The device also has a coater assembly 136, which is disposed upstream of the roll 26. The cutter unit 134 cuts sheet 18 into pieces to form shingles. A coater assembly 136 applies a conventional sticky material, such as asphalt, to the facing surface of sheet 18 prior to the application of the granules.
In operation, the blender applicator 16 applies blended prime butt granules to the surface of the sheet 18 only in the exposed drop areas of the butt. The headlap applicator 14 then applies virgin granules to the headlap area which had not been exposed to the blender applicator. The backfall applicator 12 then applies a general coverage of granules across the entire surface of the sheet using a combination of recycled granules and virgin make-up granules. The backfall box of the backfall applicator is zoned so that the combined recycle headlap granules and virgin headlap granules are applied only in the headlap zones on the sheet.
The headlap applicator applies a thickness of less expensive headlap granules only on the non-exposed headlap area of the surface of the sheet; so that the headlap area of the surface of the sheet will ultimately have a double thickness of granules. The thickness of granules is adjusted by manual operation of control unit 101. The granules applied to the non-exposed headlap area of the sheet by means of the deflector plate 112 are applied in controlled distinctive lines.
The recycle applicator 12 applies a uniform thickness of granules to the surface of the sheet. In one embodiment of the invention, the sheet width is about forty eight inches, which includes two outer six inch wide headlap strips and one center twelve inch wide headlap strip and two intermediate twelve inch wide weather exposed butt strips, so that sheet can be cut along three cutting lines to form four longitudinal shingle strips. The recycle applicator 12, which is about forty eight inches wide, has two outer six inch wide chambers 66, 74 with recycle or scrap granules for the two outer six inch wide headlap strips. The recycle applicator 12 also has one center twelve inch wide chamber 70 with recycle or scrap granules for the one center 12 inch wide headlap strip. The recycle applicator 12 also has two intermediate twelve inch wide chambers 68, 72 with clean new backfall granules for the two intermediate twelve inch wide weather exposed butt strips.
The varigator link unit 99 is adjusted, to provide just slightly more new backfall granules to the exposed butt area than will be imbedded and accepted by the coated sheet 18.
A typical process of manufacture utilizing the granule application device 10 is as follows. A sticky, asphalt material is applied over the total facing area of sheet 18 by coater assembly 136. The blender applicator 16 dispenses blended granules over the butt area of sheet 18. The headlap applicator 14 then dispenses headlap granules over the headlap area of the sheet 18 at a rate of flow as set by an operator. The recycle applicator 12 dispenses recycled granules over the headlap granules and the butt (exposed) area on sheet 18. The blender applicator 16 and recycle applicator 12 are machine driven and dispense at a rate of flow in proportion to the rate of movement of sheet 18. Cutter unit 134 then cuts sheet 18 into elongate shingle strips by a peripheral blade, and into pieces by a transverse blade, at a rate in proportion to the speed of movement of sheet 18.
The advantages of the invention are indicated hereafter.
A. The total area available in the non-exposed headlap area is covered with less expensive headlap granules by the headlap applicator 14; and there is substantially no contamination of headlap granules in the exposed butt area.
B. Less expensive granules are applied twice to the non-exposed headlap area, in order to insure relative larger weight in the non-exposed headlap area.
C. By reducing the amount of granules applied to the exposed butt area, there is more enhancement of the blended granule drops in the exposed butt area and there is less contamination of headlap granule in the exposed butt area.
While the invention has been described in its preferred embodiment, it is to be understood that the words which have been used are words of description rather than limitation and that changes may be made within the purview of the appended claims without departing from the true scope and spirit of the invention in its broader aspects.

Claims (8)

What is claimed is:
1. A process for applying granules to a moving sheet having a headlap area and a butt area for making a shingle roofing product including:
applying a sticky material to the headlap area and the butt area of the moving sheet;
dispensing blended granules over the butt area at a rate in proportion to a rate of movement of the sheet;
dispensing headlap granules over the blended granules on the headlap area at a rate as set by an operator and independent of the rate of movement of the sheet;
dispensing recycled headlap granules over the headlap granules on the headlap area at a rate in proportion to the rate of movement of the sheet;
dispensing backfall granules over the blended granules on the butt area at a rate in proportion to the rate of movement of the sheet; and
cutting the moving sheet into shingle pieces at a rate in proportion to the rate of movement of the sheet.
2. A granule application device comprising:
a sheet having a headlap area and a butt area for travelling from an upstream end thereof to a down stream end thereof;
a blender applicator disposed near the upstream end of the sheet for dispensing blended granules to the butt area;
a recycle applicator spaced from the blender applicator and disposed near the downstream end of the sheet for dispensing recycled granules to the headlap area and for dispensing backfall granules to the butt area; and
a headlap applicator with a dispensing control disposed between the blender applicator and the recycle applicator for adjustably dispensing headlap granules to the headlap area, wherein the blender applicator has a first blender bin and a first blender chamber connected by a first drop tube and has a second blender bin and a second blender chamber connected by a second drop tube for dispensing blended granules on the butt area of the sheet, and wherein the sheet has a machine drive, and wherein the first blender chamber together with the second blender chamber has a blender machine driven roll and gate unit connected to said drive, and the recycle applicator has a recycle machine driven roll and gate unit connected to said drive, for dispensing the granules from the blender applicator and the recycle applicator at a speed of flow in proportion to the speed of the sheet, and wherein the headlap applicator with a dispensing control has a manually operated roll and gate unit for adjustably dispensing headlap granules on the headlap area of the sheet at a speed of flow as set by an operator.
3. The device of claim 2 including:
a talc drum and a slate drum disposed near the downstream end of the sheet for supporting the sheet;
a seal roll disposed near the upstream end of the sheet for supporting the sheet; and
a support structure for supporting the talc drum and slate drum and seal roll.
4. The device of claim 1, wherein the recycle applicator has a headlap bin having a first plurality of headlap tubes and has a recycle bin having a second plurality of recycle tubes and has a first plurality of headlap chambers respectively connecting to the first plurality of headlap tubes and has a second plurality of recycle chambers respectively connecting to the second plurality of recycle tubes for dispensing recycle granules on the headlap area of the sheet and for dispensing backfall granules on the butt area of the sheet.
5. The device of claim 4, wherein the headlap applicator has a plurality of headlap tubes connecting to the headlap bin and has a plurality of chambers respectively connecting to its headlap tubes for dispensing headlap granules on the headlap area of the sheet.
6. The device of claim 5 including a recycle slate conveyor having an input recycle chute disposed adjacent to the slate drum for filling the recycle bin; and including a second recycle chute disposed adjacent to the slate drum for filling the recycle chambers of the recycle applicator.
7. The device of claim 2, wherein the headlap applicator has a deflector plate having guide portions with return bends for dispensing headlap granules in straight lines defining edges of the headlap area of the sheet.
8. The device of claim 2 including a coater assembly disposed upstream of the blender applicator, and including a cutting unit disposed downstream of the recycle applicator.
US07/241,284 1988-09-07 1988-09-07 Granule application device and process Expired - Lifetime US4900589A (en)

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US07/241,284 US4900589A (en) 1988-09-07 1988-09-07 Granule application device and process
AU43158/89A AU4315889A (en) 1988-09-07 1989-08-21 Granule application device and process
PCT/US1989/003571 WO1990002609A1 (en) 1988-09-07 1989-08-21 Granule application device and process

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Cited By (23)

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US5573810A (en) * 1994-09-21 1996-11-12 Owens-Corning Fiberglas Technology Inc. Method of applying microorganism resistant granules to a continuously moving strip of asphalt coated material
US5776541A (en) * 1996-12-30 1998-07-07 Owens-Corning Fiberglas Technology Method and apparatus for forming an irregular pattern of granules on an asphalt coated sheet
US5795389A (en) * 1995-02-22 1998-08-18 Iko Industries Ltd. Method and apparatus for applying surfacing material to shingles
US5814369A (en) * 1995-12-14 1998-09-29 Environmental Reprocessing, Inc. System and method for depositing media in a pattern on a moving sheet using a media retaining member
US5997644A (en) * 1995-12-14 1999-12-07 Environmental Reprocessing, Inc. Media depositing system and method
US6220329B1 (en) 1998-03-17 2001-04-24 Tamko Roofin Products Apparatus for making laminated roofing shingles
US6582760B2 (en) 2001-04-30 2003-06-24 Owens-Corning Fiberglas Technology, Inc. Blend drop conveyor for deposition granules onto an asphalt coated sheet
US6610147B2 (en) 2001-08-31 2003-08-26 Owens-Corning Fiberglas Technology, Inc. Shingle granule valve and method of depositing granules onto a moving substrate
US20040086638A1 (en) * 2001-08-31 2004-05-06 Aschenbeck David P. Method of depositing granules onto a moving substrate
US6933037B2 (en) 1997-09-18 2005-08-23 Tamko Roofing Products Triple laminate roofing shingle
US20050223941A1 (en) * 2004-03-30 2005-10-13 Boyer David C Use of anti-strip agents to improve wear characteristics of pavement sealer
US20060280907A1 (en) * 2005-06-08 2006-12-14 Whitaker Robert H Novel mineral composition
US20070082126A1 (en) * 2005-10-12 2007-04-12 Aschenbeck David P Method and apparatus for efficient application of prime background shingle granules
US20070104923A1 (en) * 2005-11-04 2007-05-10 Whitaker Robert H Novel mineral composition
US20070261337A1 (en) * 2006-04-18 2007-11-15 Whitaker Robert H Novel mineral filler composition
US20080131664A1 (en) * 2006-07-26 2008-06-05 Teng Yihsien H Roofing shingle having agglomerated microorganism resistant granules
US20080173212A1 (en) * 2005-11-04 2008-07-24 Whitaker Robert H Novel mineral composition
US20090249728A1 (en) * 2006-10-17 2009-10-08 Teng Yishien H Shingle With Low Density Granules And/Or Backdust
US20110138710A1 (en) * 2009-07-02 2011-06-16 E. I. Du Pont De Nemours And Company Building-integrated solar-panel roof element systems
US20110229636A1 (en) * 2010-03-17 2011-09-22 Aschenbeck David P Apparatus and method for controlling the deposition of granules on an asphalt-coated sheet
US8782972B2 (en) 2011-07-14 2014-07-22 Owens Corning Intellectual Capital, Llc Solar roofing system
US9956579B2 (en) 2015-10-26 2018-05-01 Iko Industries Ltd. Device for dispensing granular roofing media on a moving sheet in a pattern
US10253502B2 (en) 2016-08-29 2019-04-09 Polyglass S.P.A. Apparatus and process to create 3-D pattern on material

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US1154334A (en) * 1915-01-21 1915-09-21 Flintkote Mfg Company Method of making roofing elements.
US2348578A (en) * 1940-03-20 1944-05-09 Certain Teed Prod Corp Method and apparatus for surfacing sheet material
US2661303A (en) * 1950-04-07 1953-12-01 Carey Philip Mfg Co Method of coating roofing material
US3132964A (en) * 1958-06-23 1964-05-12 Carey Philip Mfg Co Manufacture of roofing material
US3184324A (en) * 1960-11-22 1965-05-18 T K Roofing Mfg Co Method of applying granules and apparatus for doing the same
US4352837A (en) * 1977-06-20 1982-10-05 Certain-Teed Corporation Method of manufacturing roofing shingles having multiple ply appearance
US4478869A (en) * 1983-01-03 1984-10-23 Owens-Corning Fiberglas Corporation Applying granules to strip asphaltic material

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US1154334A (en) * 1915-01-21 1915-09-21 Flintkote Mfg Company Method of making roofing elements.
US2348578A (en) * 1940-03-20 1944-05-09 Certain Teed Prod Corp Method and apparatus for surfacing sheet material
US2661303A (en) * 1950-04-07 1953-12-01 Carey Philip Mfg Co Method of coating roofing material
US3132964A (en) * 1958-06-23 1964-05-12 Carey Philip Mfg Co Manufacture of roofing material
US3184324A (en) * 1960-11-22 1965-05-18 T K Roofing Mfg Co Method of applying granules and apparatus for doing the same
US4352837A (en) * 1977-06-20 1982-10-05 Certain-Teed Corporation Method of manufacturing roofing shingles having multiple ply appearance
US4478869A (en) * 1983-01-03 1984-10-23 Owens-Corning Fiberglas Corporation Applying granules to strip asphaltic material

Cited By (34)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5573810A (en) * 1994-09-21 1996-11-12 Owens-Corning Fiberglas Technology Inc. Method of applying microorganism resistant granules to a continuously moving strip of asphalt coated material
US5795389A (en) * 1995-02-22 1998-08-18 Iko Industries Ltd. Method and apparatus for applying surfacing material to shingles
US5814369A (en) * 1995-12-14 1998-09-29 Environmental Reprocessing, Inc. System and method for depositing media in a pattern on a moving sheet using a media retaining member
WO1999019078A1 (en) 1995-12-14 1999-04-22 Environmental Reprocessing, Inc. Media depositing system and method
US5997644A (en) * 1995-12-14 1999-12-07 Environmental Reprocessing, Inc. Media depositing system and method
US5776541A (en) * 1996-12-30 1998-07-07 Owens-Corning Fiberglas Technology Method and apparatus for forming an irregular pattern of granules on an asphalt coated sheet
WO1998029196A1 (en) * 1996-12-30 1998-07-09 Owens Corning Method and apparatus for forming an irregular pattern of granules on an asphalt coated sheet
US6933037B2 (en) 1997-09-18 2005-08-23 Tamko Roofing Products Triple laminate roofing shingle
US6220329B1 (en) 1998-03-17 2001-04-24 Tamko Roofin Products Apparatus for making laminated roofing shingles
US6544374B2 (en) 1998-03-17 2003-04-08 Tamko Roofing Products Method for making laminated roofing shingles
US6582760B2 (en) 2001-04-30 2003-06-24 Owens-Corning Fiberglas Technology, Inc. Blend drop conveyor for deposition granules onto an asphalt coated sheet
US7163716B2 (en) 2001-08-31 2007-01-16 Owens Corning Fiberglas Technology, Inc. Method of depositing granules onto a moving substrate
US20040086638A1 (en) * 2001-08-31 2004-05-06 Aschenbeck David P. Method of depositing granules onto a moving substrate
US6610147B2 (en) 2001-08-31 2003-08-26 Owens-Corning Fiberglas Technology, Inc. Shingle granule valve and method of depositing granules onto a moving substrate
CN1307006C (en) * 2001-08-31 2007-03-28 欧文斯科尔宁格公司 Shingle granule valve and method of depositing granules onto a moving substrate
US20050223941A1 (en) * 2004-03-30 2005-10-13 Boyer David C Use of anti-strip agents to improve wear characteristics of pavement sealer
US7097703B2 (en) 2004-03-30 2006-08-29 Marathon Ashland Petroleum Co. Use of anti-strip agents to improve wear characteristics of pavement sealer
US20060280907A1 (en) * 2005-06-08 2006-12-14 Whitaker Robert H Novel mineral composition
US20070082126A1 (en) * 2005-10-12 2007-04-12 Aschenbeck David P Method and apparatus for efficient application of prime background shingle granules
US7638164B2 (en) 2005-10-12 2009-12-29 Owens Corning Intellectual Capital, Llc Method and apparatus for efficient application of prime background shingle granules
US20080173212A1 (en) * 2005-11-04 2008-07-24 Whitaker Robert H Novel mineral composition
US20070104923A1 (en) * 2005-11-04 2007-05-10 Whitaker Robert H Novel mineral composition
US7651559B2 (en) 2005-11-04 2010-01-26 Franklin Industrial Minerals Mineral composition
US7833339B2 (en) 2006-04-18 2010-11-16 Franklin Industrial Minerals Mineral filler composition
US20070261337A1 (en) * 2006-04-18 2007-11-15 Whitaker Robert H Novel mineral filler composition
US20080131664A1 (en) * 2006-07-26 2008-06-05 Teng Yihsien H Roofing shingle having agglomerated microorganism resistant granules
US20090249728A1 (en) * 2006-10-17 2009-10-08 Teng Yishien H Shingle With Low Density Granules And/Or Backdust
US7805909B2 (en) 2006-10-17 2010-10-05 Teng Yishien H Shingle with low density granules and/or backdust
US20110138710A1 (en) * 2009-07-02 2011-06-16 E. I. Du Pont De Nemours And Company Building-integrated solar-panel roof element systems
US8511006B2 (en) 2009-07-02 2013-08-20 Owens Corning Intellectual Capital, Llc Building-integrated solar-panel roof element systems
US20110229636A1 (en) * 2010-03-17 2011-09-22 Aschenbeck David P Apparatus and method for controlling the deposition of granules on an asphalt-coated sheet
US8782972B2 (en) 2011-07-14 2014-07-22 Owens Corning Intellectual Capital, Llc Solar roofing system
US9956579B2 (en) 2015-10-26 2018-05-01 Iko Industries Ltd. Device for dispensing granular roofing media on a moving sheet in a pattern
US10253502B2 (en) 2016-08-29 2019-04-09 Polyglass S.P.A. Apparatus and process to create 3-D pattern on material

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WO1990002609A1 (en) 1990-03-22

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